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Cooling System (Ls, Aj): Removal & Installation Mazda 6 GG рестайлинг

Cooling System (Mechanical) 8 illustrations ~830 words

ENGINE COOLANT REPLACEMENT [L3, AJ]

WARNINGNever remove the cooling system cap or loosen the radiator drain plug while the engine is running, or when the engine and radiator are hot. Scalding engine coolant and steam may shoot out and cause serious injury. It may also damage the engine and cooling system. Turn off the engine and wait until it has cooled. Even then, be very careful when removing the cap. Wrap a thick cloth around it and slowly turn it counterclockwise to the first stop. Step back while the pressure escapes. (L3) When you are sure all the pressure is gone, press down on the cap using the cloth, turn it, and remove it. (L3) Turn off the engine and wait until it has cooled. Even then, be very careful when removing the cap. Wrap a thick cloth around it and slowly turn it counterclockwise 2.5 turns. Step back while the pressure escapes. (AJ) When you are sure all the pressure is gone, turn the cap using the cloth, and remove it. (AJ)
CAUTIONUse engine coolant at a concentration that meets the environmental conditions in which the vehicle is driven, otherwise engine damage could occur. The engine has aluminum parts and must be protected by an ethylene-glycol based coolant to prevent corrosion and freezing. Do not use coolants containing Alcohol, Methanol, Borate or Silicate. These coolants could damage the cooling system. Use only soft (demineralized) water in the coolant mixture. Water that contains minerals will cut down on the coolant's effectiveness. Engine coolant damages paint. If engine coolant does get on a painted surface, rinse it off quickly.

Note. If the "FL22" mark is shown on or near the cooling system cap, use FL22 type engine coolant. FL22 type engine coolant is shipped as a diluted solution (55% coolant, 45% water). Use the solution as is when replacing coolant.

Scheme 16

Scheme 16
Scheme 16
  1. Remove the cooling system cap and the radiator drain plug.
  2. Drain the engine coolant into a container.
  3. Flush the cooling system with water until all traces of color are gone.
  4. Let the system drain completely.
  5. Tighten the radiator drain plug.
  6. Referring to the following chart, select proper volume percentage of the water and engine coolant. Antifreeze solution mixture percentage (Except FL22 type engine coolant) ENGINE COOLANT PROTECTION SPECIFICATION Engine coolant protection Volume percentage (%) Gravity at 20 °C {68 °F} Water Coolant Above -16 °C {3 °F} 65 35 1.057 Above -26 °C {-15 °F} 55 45 1.072 Above -40 °C {-40 °F} 45 55 1.086
  7. Slowly pour the engine coolant into the radiator up to the engine coolant filler port. (L3 engine model)
  8. Fill the engine coolant into the engine coolant reserve tank up to the F mark on the engine coolant reserve tank.
  9. Tighten the cooling system cap. CAUTION: If the water temperature gauge rises too high, stop the engine and decrease the water temperature to prevent overheating. Then, verify the malfunctioning part and repair or replace it. If the engine coolant level in the coolant reserve tank is below the L mark during engine coolant air bleeding operation, stop the engine, and after the engine coolant temperature decreases, add engine coolant. Then, resume the engine coolant air bleeding operation.
  10. Start the engine and idle it until the cooling fan operates.
  11. After engine warms up, perform the following steps. Run the engine at 2,500 RPM for 5 min . Run the engine at 3,000 RPM for 5 s , then idle. Repeat steps (2) several times. Idle the engine for 1 min .
  12. Stop the engine and wait until it is cool.
  13. Inspect the engine coolant level. If it is low, repeat Steps 7 -- 13 (L3 engine model), Steps 8 -- 13 (AJ engine model).
  14. Install the cooling system cap.
  15. Inspect for engine coolant leakage. (See «ENGINE COOLANT LEAKAGE INSPECTION [L3, AJ]»(ref-244562-S32425566942006092500000) ).

Water Pump Installation Note (AJ)

  1. Tighten the bolts to the specified torque, then tighten them further 85°-95° . Tightening torque 10 N.m {102 kgf.cm, 89 in.lbf}

Scheme 17

Scheme 17: L3
Scheme 17: L3
  1. Disconnect the negative battery cable.
  2. Remove the shroud panel. (See «SHROUD PANEL REMOVAL/INSTALLATION»(ref-244606-S04058949922006092500000) ).
  3. Remove the cooler pipe stay. (See «CONDENSER REMOVAL/INSTALLATION [L3, AJ]»(ref-244610-S02066621512006092500000) ).
  4. Remove the oil hose stay. (ATX)
  5. Remove in the order indicated in the table.
  6. Install in the reverse order of removal.

Scheme 18

Scheme 18: AJ
Scheme 18: AJ
  1. Disconnect the negative battery cable.
  2. Drain the engine coolant. (See «ENGINE COOLANT REPLACEMENT [L3, AJ]»(ref-244562-S33728526672006092500000) ).
  3. Remove the shroud panel. (See «SHROUD PANEL REMOVAL/INSTALLATION»(ref-244606-S04058949922006092500000) ).
  4. Remove the cooler pipe stay. (See «CONDENSER REMOVAL/INSTALLATION [L3, AJ]»(ref-244610-S02066621512006092500000) ).
  5. Remove the oil hose stay. (ATX)
  6. Disconnect the engine coolant reserve hose from the radiator.
  7. Remove in the order indicated in the table.
  8. Install in the reverse order of removal.
  9. Add the engine coolant. (See «ENGINE COOLANT REPLACEMENT [L3, AJ]»(ref-244562-S33728526672006092500000) ).

L3

  1. Verify that the battery is fully charged. (See «BATTERY INSPECTION [L3, AJ]»(ref-244569-S20283296362006092500000) ).
  2. Connect the battery positive voltage and an ammeter to the fan motor connector.
  3. Verify that the fan motor operates smoothly at the standard current draw. If not within the specification, replace the fan motor. Standard current [12 V] 8.5-11.5 (A)

High (Cooling fan motor No.1 and No.2)

Scheme 19

Scheme 19
Scheme 19

Middle (Cooling fan motor No.2)

Scheme 20

Scheme 20
Scheme 20

Low (Cooling fan motor No.1 and No.2)

Scheme 21

Scheme 21
Scheme 21

Scheme 22

Scheme 22: AJ
Scheme 22: AJ
  1. Verify that the battery is fully charged. (See «BATTERY INSPECTION [L3, AJ]»(ref-244569-S20283296362006092500000) ).
  2. Disconnect the fan control module connector (3 terminals).
  3. Connect the positive battery voltage and an ammeter to the fan control module connector on fan motor side. (2 terminals)
  4. Verify that the fan motor operates smoothly at the standard current draw. If not within the specification, replace the fan motor. Standard current [12 V] 11.8-14.8 (A)
  5. Perform the same procedure as Step 2 for the cooling fan motor No.2.

Scheme 23

Scheme 23: FAN CONTROL MODULE INSPECTION [AJ]
Scheme 23: FAN CONTROL MODULE INSPECTION [AJ]
  1. Remove the two bolts from the fan control module with the connectors still connected.
  2. Start and warm up the engine.
  3. Monitor the engine coolant temperature with the WDS or equivalent.
  4. Measure the voltage at the terminal B of fan control module connector (2 terminals) as shown in the table. If there is any malfunction, replace the fan control module. ENGINE COOLANT TEMPERATURE SPECIFICATION Inspection Result Condition A/C Engine coolant temp. IG SW ON OFF 95 °C {203 °F} or less Fan stops IG SW ON (Idling) OFF 95 °C {203 °F} or less Fan stops IG SW ON (Idling) ON (1) 95 °C {203 °F} or less 6.9V-12.1V IG SW ON (Idling) OFF 100 °C {212 °F} or more 0.6V-14.6V (1) When the magnetic clutch and the middle pressure SW are on.

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